Disconnect switch for treadmill

ABSTRACT

A treadmill has a treadmill frame and a treadmill belt movably mounted on the treadmill frame. An air space exists between the treadmill belt and a support surface on which the treadmill is placed at a rear of the treadmill belt. A disconnect switch is positioned to engage an object entering the air space. The disconnect switch is operatively connected to the treadmill motor so that the treadmill motor automatically shuts off when the disconnect switch is activated.

TECHNICAL FIELD

The present disclosure relates generally to safety, or disconnect switches for mechanical apparatus, including motorized treadmills.

BACKGROUND

Existing treadmills when in use create a health and injury risk for small children, pets and for the user as a result of the air space between the roller and belt at the back of the treadmill and the floor surface on which the treadmill is placed. Treadmills typically have a disconnect switch on a control panel that will operate to stop the operation of the treadmill, and thus stop the motion of the treadmill belt if the user falls or moves a distance away from the disconnect switch location. The safety disconnect switch on a treadmill, or safety shutoff switch as it may be referred to, typically takes the form of a key inserted into a key slot. The key is attached to a lanyard, which can then be attached to the user. The key may be a magnetic key that when inserted into the key slot allows the circuit that provides power to the treadmill motor to be completed, so that the treadmill motor will run and rotate the treadmill rollers to move the treadmill belt. When the key is removed, for example as a result of the operator falling, or moving away from the key slot, the key will be dislodged, the circuit broken, and the treadmill motor will automatically shut off and cease to operate until the key is once again inserted.

There is no known mechanism that operates to stop the treadmill from operating when an object passes between the back of the treadmill and the floor surface on which the treadmill is operating. At the back of the treadmill the belt coming backwards along the top wraps around the back roller and returns to the front underneath. The forward motion of the returning belt creates a risk of injury when an object (including a small pet or child) gets caught between the floor surface and the returning belt, and friction and weight “suck” the object under the treadmill.

A conventional guard over the belt has been tried, (e.g., U.S. Pat. No. 6,860,839 B1) but is unsuitable because no matter where the guard is placed, the space between the leading edge of the guard and the belt becomes a pinch point which can be more dangerous than the instances when an object goes under the belt. When the object that goes under is alive, it is a serious incident that has caused injuries and at least one child death.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a treadmill.

FIG. 2 is a view from the back of the treadmill showing a safety disconnect switch.

FIG. 3 is a top view of the back of the treadmill.

FIG. 4 is a view from the back of the treadmill showing an alternative embodiment of a safety disconnect switch.

FIG. 5 is view of the back of the treadmill showing another alternative embodiment of a safety disconnect switch.

DESCRIPTION OF AN EMBODIMENT

Disclosed herein is a treadmill 10 with a disconnect system 5 for stopping the operation of the treadmill 10 when an object enters the air space 12 between treadmill 10 and the floor surface 14 on which treadmill 10 is placed. Treadmill 10 has a control panel 16. Treadmill 10 will typically have a safety shutoff switch on control panel 16, which can take the form of a slot 18 for receiving a key 25, which may be for example a magnetic key comprising a round plastic disc with a magnet. A lanyard, or strap 30 is connected to the key 25 so that the key 25 can be attached to the person on the treadmill. The magnet in the key 25 completes a circuit so that when the power switch is turned on, power is provided to the treadmill motor 22. When the key 25 is not in place in the slot 18 (for instance, when the user falls and pulls on the lanyard) the removal of the key 25 breaks the circuit and the treadmill motor 22 will not operate.

The disconnect system of the current disclosure may comprise a safety disconnect, or safety shutoff switch 20 that operates to automatically stop the operation of treadmill 10 when an object is pulled under the treadmill belt at the rear thereof. FIG. 3 shows the disconnect system 5 when the disconnect switch 20 has been activated to render the treadmill inoperable and thus stop the treadmill 10 from operating. When activated, the switch 20 breaks the circuit that provides power to the treadmill motor 22. The treadmill motor 22 will cease to operate as a result of the breaking of the circuit, and the treadmill belt 32 will stop moving.

The treadmill belt 32 is mounted to a treadmill frame 33 and wraps around a roller 34 at the back 36 of the treadmill 10. Air space 12 is defined between belt 32 and floor surface 14. Below the treadmill belt 32 at the back, or rear 36 of the treadmill 10 is disconnect switch 20. Disconnect switch 20 may be in line with the roller 34. Disconnect switch 20, when activated, will stop the operation of treadmill 10 when an object enters space 12 by automatically stopping the operation of treadmill motor 22. Disconnect switch 20 in one embodiment comprises keys 42 which may include a first, or left side key 44 and a second, or right side key 46. The keys 44 and 46 comprise keys that are similar to the key 25 and may be plastic discs with a magnet therein. However, the “lanyard” in this case is an extension connected to the keys 44 and 46. Keys 44 and 46 have first and second extensions 48 and 50 extending therefrom. Keys 44 and 46 will be received in key slots 47 and 49 defined in the base 52 of treadmill 10 at the back or rear 36 thereof. Air space 12 extends between first and second sides 53 and 55 of base 52 at the rear 36 of treadmill 10. In an embodiment the end of the rods 48 and 50 may define the keys 44 and 46 that are inserted in key slots 47 and 49 respectively. Extensions 48 and 50 are stiff enough such that an object entering space 12 will move the extension that has been engaged by the object forward, causing the key connected thereto to be removed, or dislodged from the slot in which it is inserted. For example, extensions 48 and 50 may be fiberglass rods that are slightly shorter than half the width of the belt. The rods may be for example about one half inch shorter than the width of the belt 34. When in place, the first and second rods 48 and 50 extending from the first and second keys 44 and 46 extend across the space 12 between the returning belt 32 and the floor surface 14, almost meeting in the middle. Although fiberglass rods are disclosed as an example, extensions, or rods 48 and 50 may be made of any material that is sufficiently stiff to move when engaged by an object being pulled underneath treadmill belt 32.

With the treadmill 10 running, if something (object, animal or human) gets in space 12 under the back 36 of the treadmill 10 and gets pushed forward by treadmill belt 32, the object will push on at least one of the first and second rods 48 and 50. This is shown in FIG. 3 . As either of rods 48 and 50 rotate forward, the connected key 44 or 46 will disconnect from base 52. In other words, the impacted key will be dislodged from its respective slot a sufficient amount to cut off power to the treadmill motor 22 and render the treadmill 10 inoperable. Once the object is removed from space 12 the key is easy to replace in position, resetting the treadmill motor 22 and allowing the treadmill 10 to be used again. If someone bumps or otherwise dislodges either of the first and second keys 44 and 46, they are easy to reset. Because the keys 44 and 46 are very easy to disrupt, the failure mode is “safe.” The keys 44 and 46 operate similarly to the key 25, in that when inserted into their respective slots 47 and 49, the circuit that provides power to the treadmill motor 22 is complete, so that when the power switch for treadmill 10 is on, the treadmill 10 will operate. When the disconnect switch 20 is activated (i.e., one of the keys 44 and 46 is dislodged from its key slot) the circuit is broken and the treadmill motor 22 will stop, resulting in the movement of the treadmill belt 32 stopping as well.

Another embodiment of a disconnect system is shown in FIG. 4 . The disconnect system of FIG. 4 may comprise a disconnect switch 60. Disconnect switch 60 may comprise sensor 62. Sensor 62 may comprise a light emitter 64 and a light receiver 66, which may be for example similar to sensors used with garage doors to prevent the garage door from closing when an object is underneath. Light emitter 64 will emit a light beam 68 that extends laterally across the space 12 between first and second sides 53 and 55 at the rear end 36 of treadmill 10. The uninterrupted light beam 68 completes the circuit that allows power to be provided to treadmill motor 22 to drive treadmill belt 32. When an object enters space 12, the light beam 68 is broken, which automatically shuts off treadmill motor 22 by interrupting the circuit that allows power to treadmill motor 22.

Another embodiment of a disconnect system is shown in FIG. 5 . The disconnect system of FIG. 5 is similar to that described with respect to FIG. 3 , except that a single extension connects two separate keys. Disconnect switch 70 may comprise a cord, or cable 72 which may have first and second keys 74 and 76 connected at first and second ends 78 and 80 thereof. First and second keys 74 and 76 may be inserted into first and second key slots 82 and 84. When an object enters space 12, the cord 72 will be pushed forward, causing one, or both of first and second keys 74 and 76 to be dislodged from their respective slots 82 and 84, which will break the circuit that allows power to treadmill motor 22. Once this occurs, treadmill belt 32 will stop moving, thus averting injury or damage to the object. The extensions 48 and 50, light beam 68 and cable 72, or other movable or disruptable barrier used to activate a disconnect switch as disclosed herein may be referred to herein as sensor bars.

As disclosed herein, there are any number of disconnect methods and switches that may be utilized, including but not limited to: limit switches attached to arms, a cable attached to pull switches, optical switches similar to garage door safety gates. Any type of switch that is engaged (or disengaged) due to the dislodging of a “sensor bar” of some type (rod, chain, cable, light beam, etc.) by an object going under the back of the treadmill such that the power to the treadmill is disconnected may be used. The disconnect system may connect directly to the treadmill motor by a wired or wireless connection so that when the key is dislodged, or the light beam broken the treadmill motor automatically shuts off. The disconnect system may likewise be connected by wires, or wirelessly to the key and slot arrangement on the control panel, so that the dislodging of the key on the control panel, or the key or light beam at the back of the treadmill 10 will break the power circuit to the treadmill motor.

Embodiments include:

Embodiment 1. A treadmill comprising a treadmill frame, a treadmill belt movably mounted on the treadmill frame, the belt driven by a treadmill motor. The treadmill belt and a support surface on which the treadmill is placed define an air space at a rear of the treadmill belt. A disconnect switch is positioned to engage an object entering the air space at the rear of the treadmill. The disconnect switch is operatively connected to the treadmill motor so that the treadmill motor automatically shuts off when the disconnect switch is activated.

Embodiment 2. The treadmill of embodiment 1, the disconnect switch comprising a safety sensor emitting a light beam across the air space, wherein the treadmill motor automatically shuts off if the light beam is interrupted.

Embodiment 3. The treadmill of embodiment 2, the safety sensor comprising a light emitting unit on a first side of the treadmill and a light receiving unit on a second side of the treadmill.

Embodiment 4. The treadmill of embodiment 1, the disconnect switch comprising a key slot operably connected to the treadmill motor; a key insertable into the key slot; and a rigid rod connected to the key and extending across at least a portion of the air space. The deflection of the rod by an object at the rear end of the treadmill will dislodge the key and shut down the treadmill motor.

Embodiment 5. The treadmill of embodiment 4, further comprising a second key slot on an opposite side of the treadmill at the rear end thereof a second key insertable into the second key slot; and a second rigid rod connected to the second key and extending across at least a portion of the air space.

Embodiment 6. A treadmill disconnect system comprising a sensor bar positioned in an air space between a treadmill belt and a support surface on which the treadmill is placed at a rear end of the treadmill, the sensor bar extending laterally from a first side of the treadmill in a direction toward a second side of the treadmill spanning at least a portion of the distance between the first and second sides of the treadmill, the sensor bar operatively connected to a treadmill motor such that engagement of the sensor bar by an object entering the air space shuts the treadmill motor off.

Embodiment 7. The treadmill disconnect system of embodiment 6, the sensor bar comprising a rigid bar, the disconnect system further comprising a key slot in the treadmill, an end of the rod being inserted into the key slot, wherein dislodgement of the rod from the key slot resulting from the engagement of the object with the rod interrupts the power circuit for the treadmill motor to shut off the treadmill motor.

Embodiment 8. The treadmill disconnect system of embodiment 6, further comprising a light emitter attached to the first side of the treadmill and a light receiver connected to the second side of the treadmill. The sensor bar comprising a light beam extending laterally across the air space from the light emitter to the light receiver. At least one of the light receiver or light emitter is operatively connected to the treadmill motor so that interruption of the light beam shuts off the treadmill motor.

Embodiment 9. The treadmill disconnect system of embodiment 6, further comprising first and second key slots on the first and second sides of the treadmill and a cable having keys connected at first and second ends thereof inserted into the first and second key slots. The dislodgement of either of the first or second keys automatically shuts off the treadmill motor.

Embodiment 10. The treadmill disconnect system of embodiment 6 comprising a key and a key slot defined in the treadmill at the back thereof. The treadmill is inoperable when the key is not in the key slot. The sensor bar comprises a rod extending from the key across at least a portion of the distance from the first side of the treadmill to the second side of the treadmill. The rod is connected to the key such that when an object moves the rod in a direction toward a front of the treadmill, the key is dislodged from the key slot to shut off the treadmill motor.

Embodiment 11. The treadmill disconnect system of embodiment 10 comprising first and second keys and first and second key slots for receiving the first and second keys. The treadmill is inoperable when either of the first and second keys is not in its respective key slot. The sensor bar comprises first and second rods extending from the first and second keys across a distance of almost half the width of the space. The first and second rods are connected to the first and second keys such that when an object moves the either of the first or second rods in a direction toward the front of the treadmill, the key connected to the rod that is moved will at least partially dislodge from its key slot and render the treadmill inoperable.

Embodiment 12. A treadmill comprising a treadmill frame, front and rear treadmill rollers mounted to the treadmill frame and a treadmill motor mounted to the frame. The treadmill motor rotates at least one of the front and rear treadmill rollers. A treadmill belt is wrapped around the front and rear treadmill rollers and the rotation of the at least one of the front and rear treadmill rollers moves the treadmill belt. A disconnect switch is operably connected to the treadmill motor. The disconnect switch is mounted to the treadmill frame at a rear thereof and positioned so that an object entering an air space between the treadmill belt and a floor surface at the rear of the treadmill will activate the disconnect switch and automatically shut off power to the treadmill motor to stop the movement of the treadmill belt.

Embodiment 13. The treadmill of embodiment 12, the disconnect switch comprising a sensor bar extending across a least a portion of the distance from a first side of the treadmill frame to a second side of the treadmill frame in the air space at the rear thereof, the disconnect switch being activated when the sensor bar is engaged by the object entering an air space.

Embodiment 14. The treadmill of embodiment 13, the sensor bar comprising a light beam extending from the first to the second sides of the treadmill frame.

Embodiment 15. The treadmill of embodiment 13, the sensor bar comprising a rod connected to a key, the key insertable into a key slot in the treadmill frame, wherein the disconnect switch is activated when the key is dislodged from the key slot.

Therefore, the apparatus, methods, and systems of the present disclosure are well adapted to attain the ends and advantages mentioned as well as those that are inherent therein. The particular embodiments disclosed above are illustrative only, as the present disclosure may be modified and practiced in different but equivalent manners apparent to those skilled in the art having the benefit of the teachings herein. Furthermore, no limitations are intended to the details of construction or design herein shown, other than as described in the claims below. It is, therefore, evident that the particular illustrative embodiments disclosed above may be altered or modified and all such variations are considered within the scope and spirit of the present disclosure.

As used herein, the words “comprise,” “have,” “include,” and all grammatical variations thereof are each intended to have an open, non-limiting meaning that does not exclude additional elements or steps. It should also be understood that, as used herein, “first,” “second,” and “third,” are assigned arbitrarily, and the mere use of the word “first” does not require that there be any “second,” and the mere use of the word “second” does not require that there be any “third,” etc. 

What is claimed is:
 1. A treadmill comprising: a treadmill frame; a treadmill belt movably mounted on the treadmill frame, the belt driven by a treadmill motor, the treadmill belt and a support surface on which the treadmill is placed defining an air space at a rear of the treadmill belt; and a disconnect switch positioned to engage an object entering the air space at the rear of the treadmill, the disconnect switch operatively connected to the treadmill motor so that the treadmill motor automatically shuts off when the disconnect switch is activated.
 2. The treadmill of claim 1, the disconnect switch comprising a safety sensor emitting a light beam across the air space, wherein the treadmill motor automatically shuts off if the light beam is interrupted.
 3. The treadmill of claim 2, the safety sensor comprising: a light emitting unit on a first side of the treadmill; and a light receiving unit on a second side of the treadmill.
 4. The treadmill of claim 1, the disconnect switch comprising: a key slot operably connected to the treadmill motor; a key insertable into the key slot; and a rigid rod connected to the key and extending across at least a portion of the air space, wherein the deflection of the rod by an object at the rear end of the treadmill will dislodge the key and shut down the treadmill motor.
 5. The treadmill of claim 4, further comprising: a second key slot on an opposite side of the treadmill at the rear end thereof; a second key insertable into the second key slot; and a second rigid rod connected to the second key and extending across at least a portion of the air space.
 6. A treadmill disconnect system comprising a sensor bar positioned in an air space between a treadmill belt and a support surface on which the treadmill is placed at a rear end of the treadmill, the sensor bar extending laterally from a first side of the treadmill in a direction toward a second side of the treadmill spanning at least a portion of the distance between the first and second sides of the treadmill, the sensor bar operatively connected to a treadmill motor such that engagement of the sensor bar by an object entering the air space shuts the treadmill motor off
 7. The treadmill disconnect system of claim 6, the sensor bar comprising a rigid bar, the disconnect system further comprising: a key slot in the treadmill, an end of the rod being inserted into the key slot, wherein dislodgement of the rod from the key slot resulting from the engagement of the object with the rod interrupts the power circuit for the treadmill motor to shut off the treadmill motor.
 8. The treadmill disconnect system of claim 6, further comprising: a light emitter attached to the first side of the treadmill; and a light receiver connected to the second side of the treadmill, the sensor bar comprising a light beam extending laterally across the air space from the light emitter to the light receiver, at least one of the light receiver or light emitter operatively connected to the treadmill motor so that interruption of the light beam shuts off the treadmill motor.
 9. The treadmill disconnect system of claim 6, further comprising: first and second key slots on the first and second sides of the treadmill; and a cable having keys connected at first and second ends thereof inserted into the first and second key slots, wherein dislodgement of either of the first or second keys automatically shuts off the treadmill motor.
 10. The treadmill disconnect system of claim 6 comprising: a key; a key slot defined in the treadmill at the back thereof, the treadmill being inoperable when the key is not in the key slot; and the sensor bar comprising a rod extending from the key across at least a portion of the distance from the first side of the treadmill to the second side of the treadmill, the rod connected to the key such that when an object moves the rod in a direction toward a front of the treadmill, the key is dislodged from the key slot to shut off the treadmill motor.
 11. The treadmill disconnect system of claim 10 comprising: first and second keys; first and second key slots for receiving the first and second keys, the treadmill being inoperable when either of the first and second keys is not in its respective key slot; and the sensor bar comprising first and second rods extending from the first and second keys across a distance of almost half the width of the space, the first and second rods connected to the first and second keys such that when an object moves the either of the first or second rods in a direction toward the front of the treadmill, the key connected to the rod that is moved will at least partially dislodge from its key slot and render the treadmill inoperable.
 12. A treadmill comprising: a treadmill frame; front and rear treadmill rollers mounted to the treadmill frame; a treadmill motor mounted to the frame, wherein the treadmill motor rotates at least one of the front and rear treadmill rollers; a treadmill belt wrapped around the front and rear treadmill rollers wherein the rotation of the at least one of the front and rear treadmill rollers moves the treadmill belt; a disconnect switch operably connected to the treadmill motor, the disconnect switch mounted to the treadmill frame at a rear thereof and positioned so that an object entering an air space between the treadmill belt and a floor surface at the rear of the treadmill will activate the disconnect switch and automatically shut off power to the treadmill motor to stop the movement of the treadmill belt.
 13. The treadmill of claim 12, the disconnect switch comprising a sensor bar extending across at least a portion of the distance from a first side of the treadmill frame to a second side of the treadmill frame in the air space at the rear thereof, the disconnect switch being activated when the sensor bar is engaged by the object entering an air space.
 14. The treadmill of claim 13, the sensor bar comprising a light beam extending from the first to the second sides of the treadmill frame.
 15. The treadmill of claim 13, the sensor bar comprising a rod connected to a key, the key insertable into a key slot in the treadmill frame, wherein the disconnect switch is activated when the key is dislodged from the key slot. 